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Mfg. Operations Standards Need to Converge into a
Manufacturing Application Integration Framework
Charlie GiffordDirectorLean Production Management
Agenda
“What are the tough implementation problems (infrastructure, standards) that must be solved to
make “smart assembly” a reality?”
1.State of 21st Century Plant and Production Mgt. Technology
2.Challenges for B2M and B2B3.Interoperability Maturity Model 4.Significant Events in Mfg Operations Standards 5.What is Business-to-Manufacturing Integration?6.A View into an Evolving Manufacturing Application
Framework5 minutes of Discussion
GE’s Standards Liaison for Manufacturing Operations
Charlie Gifford, Director of Lean Production Management
–Chairman, ISA95 Best Practices Working Group–Chairman, ISA95 Part 4 Quality Test Ops Mgt Working
Group–Voting Member, ISA88 & ISA95 Committee–ISA95 Representative, ISA95/SCOR Alignment Working
Group–Information Member: ISA99–GE Representative, Mfg Interoperability Guideline
Working Group–GE Representative, MESA Technical Committee–Director, ISA Computer Technology Division 97-99–GE Representative, SCOR MAKE Committee–Chairman, Editorial Board, Industrial Computing
Magazine 98-02–Published over 35 papers on Industrial Computing–Standards Work: ISA84, 88, 95, MESA, SCOR, Many DOD
Standards
20th Century Manufacturing Flow
Aligning Mfg. Capabilities to 21st Century Challenges Mandates
Change…
Customers
Manufacturers Dist
Supplier Exchanges
Customer Exchanges
LogisticsExchanges
Suppliers
CMs
Retailers
Virtual Mfg.
Logistics Providers
Copyright @2004 AMR Research: All rights reserved.
Business Evolves into Configurable Demand-Driven Supply Chains
DC
DC
DC
DC
DC
Customer
Customer
Customer
Customer
Customer
CustomerDC – Dist. Channel
Need:ProductionCapability
Supplier
Supplier
Supplier
Supplier
Plant
Plant
Plant
Copyright @2004 AMR Research: All rights reserved.
Evaluate: Customer Value + OTD + Configured Production Capability = Profit
Margin
Copyright @2004 AMR Research: All rights reserved.
CM
CM
CM
Plant PlantCM
CM
DCsPlant
Plant
Loosely coupled capacity based on profit/value ratio or
compromise between value chain (profit) and
stream (demand)
Plant
Plant
Plant CM
CM
CM
Plant PlantCM
CM
DCsPlant
Plant
Loosely coupled capacity based on profit/value ratio or
compromise between value chain (profit) and
stream (demand)
Plant
Plant
Plant
Plant
Plant
Plant
21st Century Manufacturing Enablers:Flexibility & Real-Time Visibility
Challenges of B2M and B2B Communication and Processes
• Many different applications across the enterprise doing the same function
• No enterprise wide application and information architecture
• Several versions of “enterprise-objects” or language for Product, Customer, Order, etc.
BusinessLogistics
ManufacturingOperations
Challenges of B2M and M2M Integration
• Effective and Flexible Mfg. Operations…..HARD TO DO!• Various Forms of the MES / ERP solution:
Industry-specific production types Mixture of work order types across plant Speed and Volume of Throughput
• Standardization of work flow “best practices” Must Allow Change in Production Processes
Without requiring change in logistics system Provide a clear demarcation of MES / ERP
responsibilities and functions
Technology S Curve: Challenge Explained
MES / PM
HMI / SCADA / PLC
Also Applies to Methods Development: Delivery, Training, User, Support and Change disciplines
ERP
SCM
2006 Top Strategic Platform Investments Focus on Mfg Operations!
5%
3%
15%
21%
9%
11%
39%
4%
12%
22%
10%
14%
34%
3%
Customer Management
Product Lifecycle Management
Sourcing and Procurement
Supply Chain Management
ManufacturingOperations
Desktop software
Most Important (n=442) Largest Dollar (n=439)
Source: AMR Research 2006 IT Spend Survey
ERP
Interoperability Maturity Models Applied to Logistics and Operations
Systems•Level of Information System Interoperability (LISI) –Framework scopes connectivity level for technical interoperability–Does not account for system response required for mfg. workflows
Dept. of Defense
Efforts Now on How to Model Systems to Business Process Before
Going Live
• Levels of Conceptual Interoperability Model (LCIM) provides a framework for planning your data before modeling your application
Virginia Modeling, Analysis & Simulation Center Old Dominion University
Build Single Schema to Accelerate
Lean Manufacturing Transformation Road Map
Standardization Effect of Mfg. Application Framework
•Standardization Effect•S =Standardization• I = Improvement•Key elements behind standardization are:
• Takt time scheduling• Standard Work towards
single schema & process
• Route & Recipe verification process
• Change mgt. process
Effect of ISA95 together with Lean process and 6 Sigma production improvements
Lots of Standards Convergence Activity: 10+ Years of Work Moves
toward Product
OMACSP-88
Dennis Brandl
Supply Chain/ SCOR(4)(5)
1 2 3 4
SP-95Keith Unger
(3)(4*)
1 2 3
WBFCraig Wilkins
(1)(2)(3)(4*)
IEC6151362264
SP-99(cyber security)
Byran Singer
OAG /OASIS(3)(4)
MIMOSA(3)(4)
OPC(0)(1)(2)(3)(4)(5)
CIDXMake2Pack
Dave Chappell(1)(2)
Process Standards (ISA, IEC, ISO, ANSI)
Tech.Reports
5 6S88-S95
Lynn Craig
B2MMLEmersonBrandl
BatchMLEmersonBrandl
Machine Standards
Packagaing Workgroup
SC654 5 JWG15
ISO
S88 Part 6Thomas
Nash
OMAC-ISA ActivityOMAC
Manufacturing Infrastructure
OMAC Architecture
Group
Microsoft Man. Users Group
Machine Tool HMI-API
Step-NC
Packagaing Workgroup
PackConnect
Rick VanDyke
PackSoft
Gerd Hoppe
PackAdvantage
Bill Henderson
PackML
Fed PutnamMike Lamping
PackLearn
Dr. Ken Ryan
Make2Pack
Dave Chappell
ExecutiveCouncil
Numerous
Technical Director
Dave Bauman
OAGIS, SCOR
Level 3: Manufacturing Operations
Level 4+: Enterprise
Level 5+: Inter-Enterprise
Levels 2, 1, 0: Machine / Plant Work
OPC: DA, HDA, A&EOMAC
Discrete Process
OAGIS, SCOR
MIM
OS
A
ISA
-99
OP
C U
A ISA-95
ISA-88B2MMLOAGIS
An Integration Evolution: MIG WG Manufacturing Domain Mapping
F O U N D A T I O N
Hybrid
•Data Modeling: Real-Time Data Aggregation vs. Business Process Transactions
Business Planning & Logistics
Plant Production Scheduling,Operational Management, etc
Manufacturing Operations Management
Dispatching Production, Detailed ProductionScheduling, Reliability Assurance, ...
BatchControl
DiscreteControl
ContinuousControl 1 - Sensing of production work process,
manipulate the production work process
2 - Work unit (operation): Monitor, supervisory control and automated control of the production work process
3 - Work Unit and Flow Defined. Work flow / recipe control produces desired end products. Analyzes Work Data, Maintains records and optimizes the production process.
Time FrameDays, Shifts, hours, minutes, seconds
4 - Establishes the basic plant schedule - production, material use, delivery, and shipping. Determines inventory levels.
Time FrameMonths, weeks, days
0 - The actual production work process
ISA-95 & Purdue Hierarchy Model Defines MOM and ERP+ Domains for Information
Exchanges
ISA 95.01, .02, & .05 Standards
ISA 95.03, .04 & .06 Standards
Manufacturing Application Framework and Transformation Methodology
From ANSI/ISA-95.00.01-1995 Copyright ISA 2006. Used with permission. www.isa.org
Company Production Canonical Schema
Information Data
Model, Objects andDefinitions
Domain Definitions
Metrics ConstructionCategories
forInformation Analytics
Functional Segregation & Metrics
by Scenarios and Domain
Functions & Data Flowsof Interest
Supply Chain & Mfg. Scenario &
Metrics
Manufacturing Use Case
Metrics Customer Supplier
ProcessPurchaseOrder
AcknowledgePurchaseOrder
ShowDeliveryReceipt
ProcessInvoice
ConfirmBOD
Use Cases and Transaction Set Construction
QA
ServiceR&D InboundLogistics
- Mfg.Ops.
ProductionPackage
Inputs(Supplier)
Conversion(Mfg.)
DistributionConsumer
MaterialPrep
Out- boundLogistics
Mkting& Sales
Assembly
ISA-95 Functional Enterprise-Control Model
Procurement(5.0)
ProductionScheduling
(2.0)
Material andEnergy Control
(4.0)
ProductInventory
Control(7.0)
Product CostAccounting
(8.0)
QualityAssurance
(6.0)
ProductShipping Admin
(9.0)
OrderProcessing
(1.0)
ProductionControl
(3.0)
MaintenanceManagement
(10.0)
ResearchDevelopment& Engineering
Marketing& Sales
ISA S95 Part 1&2
From ISA-95 Copyright ISA 2004. Used with permission. www.isa.org
ISA 95: 4x4 Object Model Defines Production Work for B2M Data
Exchanges
People MaterialsEquipment
Resources
Segments
Structure / View
Production Schedule
Production Performance
Production
Product
Time
Production Capability
Capability
Product Definition
Product
4 Resource Categories 4 Information Categories
From ISA-95 Copyright ISA 2004. Used with permission. www.isa.org
First, Lets Understand Primary Drivers for MOM / ERP+ Segregation Requirements
Work Flow Complexity Matrix
Production TypesDiscrete Manufacturing Batch ProcessingContinuous ProcessingWork Order TypesEngineer-to-Order (ETO)Make-to-Order (MTO)Make-to-Stock (MTS)
9 Mfg. Scenarios (with hybrids) of Production and WO Types
Each have a specific set of business processes and rules Contributors: Legacy, Speed, Volume, Size, Compliance,
SKU Count
Packaging &Assembly
Production
Mtl. Prep
Complexity
Interoperability Interface Depends on Production Environment, Industry,
Products…
ProductionResource Mgt.
ProductionPerformance
Analysis
ProductionData Collection
ProductionExecution
ProductionDispatching
Productiontracking
DetailedProductionScheduling
Level 2 Process Control/ Plant Work
ProductDefinition Mgt.
ProductionCapability
ProductionPerformance
ProductionSchedule
ProductDefinition
P-MTS
P-MTS
B-MTO
D/B-ETO
B/P-MTO
From ISA-95 Copyright ISA 2004. Used with permission. www.isa.org
System Function Segregation & Interoperability
Determines Lean Performance
B2M
Level 2: Plant Work
Maintenance Production Quality Test Inventory
UProduction
datacollection
Productionexecution
Productionresource
management
Productiondispatching
Productiontracking
ProductionPerformance
Detailedproductionscheduling
ProductionSchedule
Productdefinition
management
Productionperformance
analysis
ProductionCapability
ProductDefinition
Maintenanceresource
management
MaintenanceResponse
Detailedmaintenancescheduling
MaintenanceRequest
Maintenancedefinition
management
MaintenanceCapability
Maintenanceanalysis
MaintenanceDefinitions
Maintenancedata
collection
Maintenanceexecution
Maintenancedispatching
Maintenancetracking
Inventory resource
management
InventoryResponse
Detailedinventoryscheduling
InventoryRequest
Inventorydefinition
management
Inventoryanalysis
InventoryCapability
InventoryDefinitions
Inventorydata
collection
Inventoryexecution
Inventorydispatching
Inventorytracking
Qualityanalysis
Qualitytest resourcemanagement
Quality TestResponse
Detailedquality testscheduling
Quality TestRequest
Qualitydefinition
management
Quality TestCapability
QualityDefinitions
Qualitytest datacollection
Quality testexecution
Quality testdispatching
Quality testtracking
Manufacturing Application (Use Case) Framework (MAF)System Architecture Must Support Continuous ImprovementMust Allow Change in Production Processes Clear demarcation of MOM / ERP+ responsibilities & functions
ISA 95.03 “- Part 3: Activity Models of MOM”
Level 4+: Extended Enterprise
From ISA-95 Copyright ISA 2004. Used with permission. www.isa.org
• Mostly at the data level• Mostly point to point• Custom program interfaces
or flat file exchange• Grows at exponential rate
Current State of Integration
Integration Technology Evolves From Data to Process Level Capabilities…
Enterprise
Application
Integration
Object Brokers
Workflow
DataReplication
& File
Transfer
Application Servers
MessageOriented
Middleware
Point to
Point (Custom)
BusinessProcess
Management
Continually Evolving
ExtractTransform
Load (ETL)
Web Services
Service
Oriented
Architecture
Enterprise
Service
Bus
Integration Architecture Patterns
© CSC 2005 All rights reserved.
BUT….Semantic Layer in Integration is Lagging
• Interoperability requires interfaces to be standardized. Only 5% of the interface is a function of the middleware. The other 95% is a function of the application semantics. (Gartner Group)
Application Integration Semantics
Messaging and Transport Services
95%
5%
Domains Addressed• eCommerce 10 Years in the
Field• Manufacturing• Logistics• CRM• ERP
70 Business Scenarios, 434 Messages (BODs) 77 Nouns (Common Objects) & 12 Verbs
Defined 7 Workgroups of new Content More localization for more International
support UN/CEFACT/ISO compliant ISO 11179, CCTS 2.01/ISO 15000-5, TBG17
BIE/ABIE
OAGIS® 9.0 Scope Provides Business Semantics
OAGIS B2M Integration: ISA95/OAGIS Convergence
Plant Functions
Product Definitions and Production Capabilities
Production Orders WIP and Inventory Status
Order Completion & Resource Consumption
BODS Sync/Get/Show ItemMaster
Sync/Get/Show Production Order
Get/Show/Update Inventory Count
Get & Show Consumption
Sync/Get/Show Inventory
Sync/Get/Show Routing
Get/Show/Confirm Inventory Issue
Allocate Costing Activity
Sync/Get/ShowUnit of Measure Group
Sync/Get/Show Dispatch List
Issue/Receive Inventory Movement
Update Inspection
Sync/Get/ShowBill Of Material
Sync/Get/Show Maintenance Order
Get/Show/Update WIP Confirm
Get/Show/Confirm Inventory Issue
Get/Show/Sync Engineering Change Document
Sync/Get/Show Planning Schedule
Process WIP Merge
Issue/Receive Inventory Movement
Sync/Get/ShowEngineering Work Document
Sync/Get/Show Sequence Schedule
Process WIP Move Show Shipment Schedule
Sync/Get/Show Planning Schedule
Sync/Get/Show Employee Schedule
Process WIP Recover
Show Shipment
Sync/Get/Show Sequence Schedule
Process WIP Split Get/Show/Update Picklist
Sync/Get/Show Inspection
Get/Show WIP Status
Time & Attendance
MAF Best Practice Transformation Methodology
Utilizes ISA95 with other Models throughout Best Practices ISA95/MESA BP Working Group: Book 1.0, December 2006 Step 1: (Define) Train Staff on Technical Applications used to benchmark & design
business process in Methodology (Steps 2-4) Step 2: (Define, Measure, Analyze) Structured Mfg. Ops. Assessment and Schema Migration PlanStep 3: (Analyze, Improve, Control) Accelerated MOM Application Implementation & TransformationStep 4: (Analyze, Improve, Control) Life Cycle Management of MOM Application, Interfaces & Metrics
Smart Assembly Need Methods for Schema, Process, & Lean 6 Sigma
Transformations• Interoperable MOM / ERP solutions require consistent:
• Production Data Model and Schema based on Work Definition
• Functional and Data Exchange Models• Consistent Message Structure from M2B and B2M• Methodology for MOM / ERP integration
• Single Production Schema Reinforces Lean practices such as: Standard work flow practices across MOM Activities:
Production, Quality, Maintenance, & Inventory Operations Schedule/Dispatch, Data entry methods, CID, ECO,
Routes, etc.Cross-training operators and mechanics:
Common work definition for operations and resourcesSingle XML production schema across all MOM
applications simplify Data Collection, Analytics, Interfaces and Reporting
Questions?
Charlie Gifford [email protected] Performance Mgt. GE Fanuc AmericaChairman, ISA-95 Best Practices Working Group